The first two pre-assembled rack modules have arrived and been installed on Barrow Island, marking a major milestone as construction ramps up. A total of 53 shipments will deliver modules to eventually form the gas processing facility. Foundations are also being laid for the 2.1km LNG jetty, with the first caisson structures placed. The project is creating opportunities for Australian businesses across the country, with over $16 billion already committed and more than 350 contracts awarded.
1. Gorgon Project
Issue 29, July 2012
Gorgon Project Update
Feature Articles
World Environment Day Award for
Gorgon
Page 2
Hands-on Experience for Apprentices
Page 3
Construction Humming as Logistics
Ramp Up
Page 4
Project Creates Opportunities for
Business Across Australia
Page 6
Strengthening Pilbara Networks
Page 8
First Pre-Assembled Racks in Place
The first shipment of pipe racks,
comprising four modules, was
offloaded at the island’s new Materials
Offloading Facility (MOF) in June where
they underwent a thorough inspection
by the Project’s quarantine team.
Gorgon Development Director Scott
Young said the team was focused on
the safe execution of the offloading
operation.
“This is the start of a major phase of
the construction effort on Barrow
Island so it is critical that the modules
The Gorgon Project is operated by
an Australian subsidiary of Chevron
and is a joint venture of the
Australian subsidiaries of Chevron
(47.3 percent), ExxonMobil (25
percent), Shell (25 percent), Osaka
Gas (1.25 percent), Tokyo Gas (one
percent) and Chubu Electric Power
(0.417 percent).
The first shipment of the pre-assembled racks (PARs) arrived on Barrow Island in June, with two modules already in position on site.
are safely transferred to site in
preparation for final installation,” Mr
Young said.
“In total, 53 module shipments are
due to arrive at site to eventually form
Gorgon’s gas processing facility.”
The largest item in the first shipment
was about 65 metres long and weighed
1,400 tonnes, and will later be followed
by modules exceeding 6,000 tonnes.
Once offloaded, the PARs are being
moved to site by self-propelled module
transporters. They will take their place
in the east-west corridor area of the
gas processing plant site.
“Over coming months, the Barrow
Island landscape will be transformed as
more PAR and Train 1 modules arrive
and are placed on their foundations,”
Mr Young said.
In a sign of major ramp up of plant
construction activity on the Gorgon Project,
the first two pre-assembled rack (PAR)
modules are now in place on Barrow Island.
2. Workforce Stands Together for Safety
The Barrow Island workforce
recently came together to
demonstrate their commitment to
safety while reflecting on the story
of one woman’s personal journey.
As part of the Stand Together
for Safety weekend in May, Helen
Fitzroy, who lost her husband in a
mining incident in Western Australia,
reminded those working on Barrow
Island of the importance of coming
home safely every day.
“The effect of losing a loved one lasts
a lifetime. You can’t even begin to
imagine how different the lives of your
family, friend and workmates will be,”
Ms Fitzroy said.
“We all know that significant incidents
don’t just happen. There are plenty of
Helen Fitzroy speaking to the Barrow Island
workforce as part of the Stand Together for
Safety weekend.
warning signs.”
Helen conducted eight sessions
over two days to share her personal
experience and her message about the
importance of valuing safety.
Gorgon Site Execution Manager Jerry
Albers echoed Ms Fitzroy’s words and
reminded the workforce that safety is a
journey requiring each person to take
responsibility for making safe choices
and the importance of following the
right procedures.
“Safety is a mindset on which all
injuries and incidents are preventable.
It is about valuing your life and your
mates,” Mr Albers said.
“We want our workforce to understand
the value of safety and use the safety
procedures we have in place to ensure
they go home safely to their families.
“We want them to remember Gorgon
as not just the biggest and most
complex project but the safest project
and take that legacy to the next job
they work on.”
The Gorgon Quarantine
Management System (QMS)
continues to receive accolades,
this time acknowledged by the
United Nations (UN) Association
of Australia for its excellence
in environmental management
and stewardship at the World
Environment Day Awards.
(L-R) Gorgon Quarantine Awareness
Coordinator, Jen O’Reilly, Chevron Australia
Quarantine Manager, Johann van der Merwe
and Gorgon Quarantine Downstream Director,
Barbara Marks accept an award for Best Practice
Program at the United Nations Association 2012
World Environment Day Awards.
World Environment Day Award for Gorgon
Announced at a presentation dinner
held in Melbourne in June, the
QMS received the Business Award
for Environmental Best Practice
Program, demonstrating excellence
in environmental management and
sustainable development, consistent
with global UN standards.
In accepting the prestigious award,
Chevron Australia’s Quarantine
Manager Johann van der Merwe
said the QMS demonstrates that
with appropriate environment
management, industry and
conservation can coexist.
“Historically, conservation and
development on this scale was thought
to be mutually exclusive, however
this system shows that sustainable
development of resources can occur
in ecologically sensitive areas,” Mr van
der Merwe said.
“The QMS is likely establishing a new
global standard and illustrates what
can be achieved when community,
government and industry work
together.”
Australia’s UN Representative Chris
Woodthorpe echoed these words when
delivering UN Secretary-General, Ban
Ki-moon’s World Environment Day
message.
“With smart policies and the right
investments, countries can protect
their environment, grow their
economies, generate decent jobs
and accelerate social progress,” Mr
Woodthorpe said.
“The comprehensive QMS consists
of more than 300 procedures,
specifications, checklists and
guidelines to protect the biodiversity
of Barrow Island and its surrounding
waters and was recognised by the
Western Australian Environmental
Protection Authority as likely to be
world’s best practice.”
2 | Gorgon Project Update
3. Hands-on Experience
for Apprentices
There’s only so much you can learn
from a book. A solid grounding
of technical knowledge, plus
hands-on experience and expert
teachers make a huge difference to
developing skills you have for life.
That’s the experience apprentices are
getting on the Gorgon Project.
One of the Gorgon apprenticeship
programs is being run by Kentz Pty
Ltd, which has 29 apprentices, with 23
based on Barrow Island between three
contracts.
Brian Merritt manages the apprentices,
along with a team of 70 Kentz
electricians, technicians and radio
specialists. For Mr Merritt, things have
The Gorgon Project has achieved
a major project milestone with the
recent installation of the first jetty
support structures at Barrow Island.
The installations, comprising a
concrete caisson and steel topside,
are the first of 56 that will be
positioned as part of the LNG jetty.
They will support the jetty roadway
trestles and piperacks.
The placement of the first jetty
come full circle.
“When I was starting out, one of the
first big projects I worked on was
the Snowy Mountains Hydro Electric
scheme. It’s only looking back now that
I realise it was such an iconic project,”
Mr Merritt said.
“And now here I am – on another iconic
project – but this time I’m teaching the
apprentices.
“Every Kentz apprentice needs to
build their skills and develop their
knowledge. Working safely is also
absolutely essential. Our team also
focuses on having pride in your
workmanship and a solid team-work
approach. These are skills that will help
you throughout your career.”
Jetty Installation Underway
caissons at Barrow Island is a
significant accomplishment for the
team, marking the start of visible
progress towards the eventual 2.1
km jetty.
Constructed by Saipem Leighton
Consortium at Henderson’s
Australian Marine Complex,
each caisson structure weighs
3500-tonnes and will be transported
to the island, four caissons at a
time, using an ocean-going tug and
Brian Merritt (far right) with a group of apprentices that are working on Barrow Island.
The development drilling campaign
in the Jansz-Io Field is underway
with the first of ten wells spudded by
the ExxonMobil operated Deepwater
Frontier drillship. Greater Gorgon
General Manager Colin Beckett
said the campaign marked another
significant 2012 milestone for the
Project.
“It is an example of the strength
of partnering to achieve strong
business outcomes and I commend
ExxonMobil, a Gorgon Joint Venture
Participant, for overseeing the safe
spudding of the first well in the
Jansz-Io Field,” Mr Beckett said.
The Transocean Deepwater
Frontier is a fifth generation, ultra
deep drillship that is dynamically
positioned, which means it is not
anchored, but is kept on location by
thrusters, GPS and a sophisticated
computer system. It can
accommodate up to 160 people and
can operate in waters up to 3,000
metres deep.
This ExxonMobil drilling campaign
is capturing numerous synergies
with the Chevron-operated Atwood
Osprey drilling program in the
nearby Gorgon Field. The 2 rigs
are sharing shorebase resources,
marine vessels, materials logistics,
and air logistics in a true spirit of
partnering for the best overall
project outcome.
Jansz-Io Drilling
Campaign Underway
specialised submersible barge.
Each caisson is installed via a
complex operation. Following pre-
ballasting, the barge is submerged
until the caisson becomes buoyant
and has suitable clearance to be
towed behind the barge.
It is then moved to installation
moorings for precise positioning on
the sea floor, which is undertaken
remotely from another vessel.
Gorgon Project Update | 3
4. Gorgon is on track to reach a
number of key milestones this
year as good progress is made on
construction activities taking place
on Barrow Island.
Gorgon Downstream Project General
Manager Jeff Brubaker said the recent
arrival of the first shipment of pre-
assembled racks (PARs) on Barrow
Island marked the start of a logistically
challenging and delicate moment in
Gorgon’s construction phase.
“This is the year where almost every
part of the Project will be in full
execution. It is the year when we will
truly see Gorgon grow,” Mr Brubaker
said.
“Right now, about 4,000 people on
the island are preparing the site for
the arrival of the first processing train
module, due later this year.”
Four PAR modules reached the island
in June and two have already been
installed in position. All up, it will take
53 shipments to bring all modules that
will make up the gas processing plant.
Timely progress is being made on the
LNG and condensate tanks while the
permanent buildings that will house the
Operations Centre are also advancing
well.
The foundations of the 2.1km LNG
jetty are taking shape with the first
caissons – or support structures –
being placed on the ocean bed. More
than 300 people are pre-fabricating
56 caissons at the Australian Marine
Complex (AMC) in Henderson. Also at
the AMC, the first main cryogenic heat
exchanger has arrived, measuring a
huge 57 metres long and weighing 630
tonnes.
Offshore Work Continues
The Gorgon Upstream construction
activities on Barrow Island are also
progressing. After the successful
installation of the nine HDD pipes
under North White’s Beach, the cross-
island pipeline construction continues.
Progress is also being made in the
complex inlet area of the LNG plant.
Upstream is constructing the large
diameter inlet gas piping so that
Downstream can follow with module
Construction Humming as
Timely progress is being made on the LNG and condensate tanks.
The plant site is humming with construction activity.
4 | Gorgon Project Update
5. Logistics Ramp Up
The construction village continues to grow.
The foundations of the 2.1km LNG jetty are
taking shape with the first caissons placed on the
ocean bed.
construction and tie-ins. This has
resulted in a very coordinated effort
between Upstream and Downstream
contractors.
Gorgon Upstream Development
Manager Kevin Shannon said offshore,
the upstream team has now drilled and
evaluated five wells in the Gorgon Field
and the first of 10 wells in the Jansz-Io
Field has been spudded by the Exxon
Mobil operated Deepwater Frontier
drillship.
“The team is also progressing with the
installation of the offshore pipelines
from the shore-crossing site to the
Gorgon and Jansz-Io fields,” Mr
Shannon said.
“We have mobilised the domestic
gas pipeline installation contractor,
SapuraClough, and its Java
Constructor construction barge
has started laying the domestic gas
pipeline off Barrow Island.
“SapuraClough has also mobilised
the mainland construction crew and
started site preparations there.”
The domestic gas export pipeline runs
some 99 kilometres from the jetty
on Barrow Island to a mainland tie-in
point with the Dampier-to-Bunbury gas
trunkline.
“The domestic gas pipeline is needed
initially during the commissioning of
the LNG plant as we plan to backflow
domestic gas to supply the gas turbine
generators during the LNG plant
commissioning. After the LNG plant is
in operation, there will be significant
gas volumes sold to the Western
Australian domestic gas market from
the project’s gas fields,” Mr Shannon
said.
“These are key milestones for the
project, but what will make these
events truly significant is when they
are delivered safely.”
The Gorgon pipeline scope is truly
massive and the importance of the
The first two pre-assembled rack modules are
now in place on site.
pipeline to the project cannot be
underestimated, with 800 kilometres
of pipe being laid – which is about the
distance from Perth to Monkey Mia –
and 71,000 joints in total. Some of the
pipelines are the most unique ever
designed and installed.
Gorgon Project Update | 5
6. Project Creates Opportunities
As Australia’s largest single
resource development, Gorgon has
already committed more than $16
billion to Australian industry and
generated more than 7,000 jobs
across the country.
Gorgon Australian Industry
Participation Coordinator Bill Sashegyi
said more than 350 contracts for work
had been issued and this was expected
to increase through the construction
period and into operations.
“The contracts have been awarded
to companies all around Australia,
from Karratha to Bunbury in Western
Australia, through to the Mornington
Peninsula, Newcastle and Brisbane
on the east coast of Australia,” Mr
Sashegyi said.
“The Gorgon Project remains on
track to deliver about $20 billion on
Australian goods and services during
the construction phase and we are
continuing to work closely with local
contractors to ensure Australian
companies realise the opportunities,”
Mr Sashegyi said.
Lasting Benefits
In Adelaide, Osmoflo has constructed
five separate desalination plants to
MPower’s temporary plant will power the entire
gas processing plant on Barrow Island during
the construction and commissioning phase.
Alstom Grid’s contract with the Gorgon Project is keeping its suppliers busy.
convert seawater into fresh drinking
and processing water.
Osmoflo Managing Director Marc Fabig
said the unique challenges presented
by the Project had enabled the
company to build its workforce.
“Doing a benchmark project like this, it
enables people to further develop their
skills – for example, designing and 3D
modelling capabilities – and that has a
long lasting benefit,” Mr Fabig said.
Powering Construction
Running Gorgon’s construction
facilities, such as the desalination
plants, requires a reliable electricity
source – a major challenge in a remote
location like Barrow Island.
Sydney-based company, MPower
has successfully delivered a solution
with the construction of a 20MW
continuously rated temporary power
plant for the entire Barrow Island
gas processing plant during the
construction and commissioning
phase. MPower Projects Managing
Director Anthony Csillag said the
company’s innovative solution is
designed to withstand category five
cyclones and minimise environmental
impacts on Barrow Island.
“What we are doing is certainly a
world-first. The space allocated on
Barrow Island was quite small for this
size power station, so we supplied the
highest density power pack per square
metre,” Mr Csillag said.
As well as drawing on MPower’s
technical expertise, the scope of the
Gorgon contract presented other
opportunities for the company’s staff.
MPower Operations Manager Eric
Nemme said the company runs a dual
trade apprenticeship program for
electrical and mechanical apprentices.
“The Gorgon Project has allowed
our apprentices to work on both the
electrical and mechanical aspects
of the Project in one hit, rather than
diversifying over various smaller scale
projects. So, it’s enabled them to do
both trades,” Mr Nemme said.
Busy Suppliers
While MPower has helped power the
construction phase of the project,
a series of contractors across
Queensland and New South Wales
are constructing the network of sub-
stations that will power Gorgon’s gas
processing plant.
Among them is Alstom Grid which
is delivering orders worth $250
million, including 41 pre-fabricated
powerhouses and 30 transformers.
Alstom Australia Managing Director
Mohan Somasi said that the company’s
contract with the Gorgon Project has
seen its staff numbers grow and has
6 | Gorgon Project Update
7. Hart Marine is fabricating a specialist 16 metre
pilot boat for the Gorgon Project.
for Business Across Australia
Osmoflo has designed and is constructing four separate desalination plants capable of producing a
total of seven megalitres of water a day.
kept its suppliers busy.
“We have employed 150 staff members
on this project. We have also employed
more than 40 contractors in Australia
– such as building suppliers, steel
contractors, wiring contractors, and
also AC distribution contractors,” Mr
Somasi said.
New Opportunities
Another contractor to have benefited
from Gorgon’s local investment is
Custom Transportable Buildings which
has been fabricating electrical switch
rooms for the Project.
Custom Transportable Buildings
Managing Director Simon Griffiths
said Gorgon has brought additional
work and skills to the Newcastle based
business.
“Prior to the Gorgon Project we used to
use electrical subcontractors whereas
now we actually have our own electrical
team,” Mr Griffiths said.
“This opens up new doors for us within
the liquefied natural gas industry.
We’ve been exposed to a lot of different
standards and specifications and now
we’re confident about going into other
projects.”
World Leader
On Victoria’s Mornington Peninsula,
boat-builder Hart Marine is fabricating
a specialist 16-metre pilot boat that will
transfer pilots to the tankers arriving
at the Barrow Island LNG jetty.
Hart Marine Managing Director Mal
Hart said the pilot boat will be a world
leader in its class of pilot boats and
comprises a range of materials built
Australia-wide.
“We have skills from laminators to
guys that are experts in the infusion
process of composite. We also do all
our own metal fabrication, so all the
stainless steel work and metalwork
that’s required for the pilot boat – from
bow rails and life buoy holders, to man
overboard recovery ramps – that’s all
built in our workshop,” Mr Hart said.
“We also install all the engines here, so
we’ve got mechanics, electrical people,
and cabinetmakers. We have a vast
array of manufacturing skilled staff
here to build this craft.
“We have lots of companies that are
involved, from paint manufacturers to
metal companies supplying stainless
steel.”
Training Local Crews
Once completed, the pilot boat will play
a key role in marine services at the
Barrow Island LNG terminal. Over the
first 20 years of Gorgon operations,
these services will be managed by
Svitzer Australia.
“As the largest maritime employer in
Australia, Svitzer will draw on a wealth
of knowledge available within the
business to ensure locally employed
crews are secured and trained to
operate these state-of-the-art tugs,”
Svitzer Australia Managing Director
Mark Malone said.
“This will include a program to employ
and train local indigenous people
with an interest in pursuing marine
qualifications.”
Gorgon Project Update | 7
8. Chevron contacts
The Gorgon Project is operated by an Australian subsidiary of Chevron and is a joint venture of the
Australian subsidiaries of Chevron (47.3 percent), ExxonMobil (25 percent), Shell
(25 percent), Osaka Gas (1.25 percent), Tokyo Gas (one percent) and Chubu Electric Power (0.417 percent).
Chevron Australia Pty Ltd
ABN 29 086 197 757
250 St Georges Tce, Perth WA 6000
Ph: +61 8 9216 4000 Fax: +61 8 9216 4166
Email: gorgon.info@chevron.com
Web: chevronaustralia.com
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Strengthening Pilbara Networks
More than 100 Pilbara business
women attended the recent Women
in Business Luncheon in Karratha.
Sponsored by the Gorgon Project, the
Pilbara Business Development Series
consisted of a Women in Business
Networking Luncheon and Business
Development Workshops held over two
days.
Small Business Centre West Pilbara
Manager Rachel Whiting said the
series provided local business women
with the opportunity to develop their
networks and gain from the experience
of the guest speakers and their
experience managing work-life balance
Key Part of MOF Completed
The final X-bloc has been laid for
the breakwater at Barrow Island’s
new Materials Offloading Facility
(MOF).
Completion of the breakwater was a
major milestone in the east MOF works,
with the remainder of the facility to
be finished in the coming months.
Designed to withstand cyclones, the
breakwater is made of 140,000 cubic
metres of reclaimed dredge material,
150,000 tonnes of rock, 24,000 square
metres of geotextile lining material and
6,550 X-blocs.
At a length of 355 metres, the
breakwater is an important part of the
MOF as it provides shelter for the works
around the Heavy Lift Facility during the
construction period. In the operations
phase it will provide a safe haven for the
vessels in the tug pen area.
Situated at the top of the Materials Offloading Facility, the breakwater will provide shelter for the
Heavy Lift Facility during the construction phase of the Project.
in the busy resource industry.
“The objective of the business
development workshops was to
provide affordable information that
is relevant to small and home-based
businesses in the region,” Mrs Whiting
said.
Greater Gorgon Asset Support
Manager Dr Julia Martin attended the
luncheon as a guest speaker.
Dr Martin, who has worked in the
resource sector for more than 25 years
as a research scientist, consultant and
environmental manager, is currently
a member of the Greater Gorgon
management team.
Dr Martin reflected on her experiences
and how she has applied these lessons
to mentoring Chevron staff on career
management.
“Participating in the event was a great
opportunity to continue to showcase
Chevron’s commitment to the Pilbara
community and developing our
people,” Dr Martin said.
The Pilbara Business Development
Series events are jointly run by the
Small Business Centre West Pilbara
and the Karratha and Districts
Chambers of Commerce and Industry
(KDCCI).
8 | Gorgon Project Update
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